Steel Thermal Stud And Method Of Manufacture Thereof

ABSTRACT

Disclosed herein is a steel thermal stud and method of manufacturing thereof. The steel thermal stud of the present invention can be used in load bearing and non-load bearing applications as a direct replacement for wood studs, however installed the same as traditional steel studs. The steel thermal stud is able to be insulated with a variety of insulation products depending on the application, and the stud discloses a superior thermal and acoustic properties while being much lighter than wood studs.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 63/243,948, filed on Sep. 14, 2021.

BACKGROUND OF THE INVENTION Field of Invention

The present invention relates primarily to a field of steel framing, and more particularly it relates to a novel and useful steel thermal stud for buildings of all types, that provides both structural and non-load bearing characteristics.

Description of Related Art

In the past, there has been a little change in structural and non-structural steel framing industry since its inception. The steel studs used today are essentially the same design and serve the same functions as when they were first introduced as a “C” shape showing a little advancement. When compared to wood studs, the steel studs have had significant advantages in many areas, but not in thermal transfer which is much worse with the steel studs.

Hence, there is a significant need and void in the market to invent a novel and improved steel thermal stud that provides both structural and non-load bearing characteristics. Also, there is a need to invent a novel and improved steel thermal stud that allows for cantilevered loads mounted perpendicular to a wall plane for items such as televisions for interiors and façade systems for exterior applications.

The present invention is hereinafter disclosed, which provides more thermally efficient steel stud with both, structural and non-load bearing characteristics, and allows for cantilevered loads mounted perpendicular to a wall plane for items such as televisions for interiors and façade systems for exterior applications. The unique characteristics and features of the present invention are, therefore, unrepresented within the conventional steel studs. Hence, the present invention has been disclosed to provide solutions to the aforementioned needs, and to resolve the aforementioned deficiencies in the conventional steel framing systems.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present application, a novel and useful steel thermal stud is herein provided that includes a pair of independent flanges with webs, an insulation material therebetween the independent flanges, and formed plates that hold the independent flanges together via the webs of the flanges.

The steel stud of the present invention may also have an additional nailing wall or flange installed, which provides additional and separated penetration locations for mounting screws, allowing multiple connection points on the screw so that they become “cantilevered” and able to support loads unlike a single walled stud.

The stud may be filled with an insulation material prior to final forming, and the insulation used within the stud may be selected from, but not limited to, foam blocks, rock mineral wool, spray in foam insulation, or other types of insulation.

It may be apparent that the novel and useful Steel Thermal Stud of the present invention has been hereinabove described which works and is used in a manner not consistent with the conventional products and methods.

It is therefore an object of the present application to provide a Steel Thermal Stud with multiple stud walls for a fastener to penetrate in order to prevent the movement of the fastener in any direction, to prevent deformation of the stud wall material, to prevent the fastener from backing out by having additional contact with less potential movement, to provide more pull-out strength and more strip resistance of the fastener during installation.

Another object of the present application is to provide a Steel Thermal Stud that allows the stud to be made as a single unit, or where the flanges with webs are used separately.

Another object of the present application is to provide a Steel Thermal Stud that uses the compressive strength of an insulation to help prevent stud components from moving when pressure is applied to them.

Another object of the present application is to provide a Steel Thermal Stud with a fastener that takes onto itself tensive, compressive, bending, shear and other forces that may otherwise be exerted to a sub-girt and/or stud, when used with either the stud and/or sub-girt of the present application, supporting the sheathing and/or insulation.

Another object of the present application is to provide a Steel Thermal Stud that eliminates the need for resilient channels and/or resilient clips.

Another object of the present application is to provide a Steel Thermal Stud with formed plates which help isolate and absorb vibration and thermal transfer.

Another object of the present application is to provide a Steel Thermal Stud with formed plates which are installed perpendicular to the flanges and webs, diagonally, and/or offset on opposing sides to assist with structural strengths and/or acoustic and thermal transfer reduction.

Another object of the present application is to provide a Steel Thermal Stud which may be used horizontally as a joist or beam, and made with aluminum extrusion in place of steel.

Another object of the present application is to provide a Steel Thermal Stud having formed plates that structurally act to connect both flanges with webs together, assist with axial and twist strengths, provide compressive and tensive strengths for increased bend strength of the complete stud assembly, essentially preventing one flange with webs from moving without the other flange with webs moving.

Another object of the present application is to provide a Steel Thermal Stud having formed plates that act as the limited thermal and acoustic bridging between the flanges with webs.

Another object of the present application is to provide a Steel Thermal Stud with the webs of the flanges being the same length, which may help to eliminate twist of the stud when loads are applied to the stud from any direction.

Another object of the present application is to provide a Steel Thermal Stud with bends in the stud that normally couldn't be made by use of aligned slots. The slots allow bends to be made by rolling the independent flanges over so that no other tooling is needed to make the bends at the aligned slots, allowing for more complex shapes to be made especially when other materials such as insulation may be in the way. For structural strength, and in lieu of the aligned slots, aligned indentations may allow for the same type of bend, with the indentations protruding to the outside of the bend once formed.

Another object of the present application is to provide a Steel Thermal Stud with a rigid insulation to be mounted within a stud part, wherein the rigid insulation may be pre-cut or grooved to consume all air gaps within the completely formed stud.

Another object of the present application is to provide a Steel Thermal Stud which may be utilized as purlin or other shape, and which may be made with fiber reinforced plastic instead of steel.

Another object of the present application is to provide a Steel Thermal Stud with a least expensive sound-proofing wall systems and highest thermal transfer resistance.

Another object of the present application is to provide a Steel Thermal Stud that minimizes or eliminates cross bracing, and/or increases the span distances that can be made.

Another object of the present application is to provide a Steel Thermal Stud that allows all known adhesives and fabrication methods to be used in any and all locations required within the framing and other components to attach them together better, to help prevent vibration (sound) travel, to help prevent thermal transfer, and/or to help increase strength.

Another object of the present application is to provide a Steel Thermal Stud, where all components, parts, structural shapes, and any other aspect of the stud is considered to be one or more in quantity and/or location.

Another object of the present application is to provide a Steel Thermal Stud, wherein the process of forming and assembly is done in a continuous manufacturing line having punches, roll forming, insulation insertion, final forming and formed plate installation.

Another object of the present application is to provide a Steel Thermal Stud which allows for the same flanges with webs to be used for multiple stud widths, such as, but not limited to, 3.5″, 3.625″, 5.5″ and 6″ stud widths.

Another object of the present application is to provide a Steel Thermal Stud which utilizes an installed plastic spacer prior forming of the final bend to prevent over-bending of the last-formed web when using light density insulation within the stud.

Another object of the present application is to provide a Steel Thermal Stud which provides an additional level of safety for cut protection by not fully exposing metal edges.

Another object of the present application is to provide a Steel Thermal Stud which may be made by employing a forming process that includes use of compression around the different stud components, and use of electro-magnetic to control the positioning of the flanges with webs during a formed plate installation to ensure proper alignment with minimal tolerances to install the formed plates simultaneously at all locations on the stud, along with alignment electronic controls.

Another object of the present application is to provide a Steel Thermal Stud which is a direct replacement for wood studs, yet be lighter and with better thermal and acoustic performance, and used with traditional steel stud tracks.

Another object of the present application is to provide a Steel Thermal Stud, the process of which allows the final bends at the aligned perforations to be over-bent, pushing into the insulation, and recovering or springing-back to the correct angle, and wherein the insulation assists in maintaining the shape of the stud both during the forming process and once the stud is ready for use.

Another object of the present application is to provide a Steel Thermal Stud which utilizes any added strengths of the insulation towards the overall structural performance of the stud.

Another object of the present application is to provide a Steel Thermal Stud which utilizes no formed plates to hold the flanges with webs together, for applications such as, non-load bearing conditions, wherein the webs of the flanges with webs may have small interior facing barbs, formed with a punch press, that penetrate the insulation to prevent separation of the flanges with webs, and to keep the insulation positioned within between the flanges with webs.

Another object of the present application is to provide a Steel Thermal Stud with flanges that have indentations with centered holes that may align with a track with matching indentations to self-align the studs at the proper locations when being installed to avoid measuring, and wherein the track may have indented obrounds with obround slots for locations with height differences.

Another object of the present application is to provide a Steel Thermal Stud with at least one secondary flange, wherein an air gap between the flanges acts as an opening for vibration to be trapped, or wherein the at least one secondary flange is a wood or similar product in place of formed steel.

The invention possesses other objects or advantages especially with concerns to particular characteristics and features thereof which will become apparent as the specification continues.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric elevation view of a stud A including a pair of top and bottom flanges of metal, each with webs, and slots punched having a specific distance between them which will match the final formed stud width, according to an embodiment of the present invention.

FIG. 2 is an isometric elevation view of the pair of top and bottom flanges of FIG. 1 in the form of parallel strips with a space therebetween, according to an embodiment of the present invention.

FIG. 3 is an isometric elevation view of the strips of FIG. 2 with a step formed on each side of each strip along its length, according to an embodiment of the present invention.

FIG. 4 is an isometric elevation view of a semi formed stud A with a first bend in both flanges with webs, and an insulation piece installed in a gap therebetween the semi formed stud A, according to an embodiment of the present invention.

FIG. 5 is an isometric plan section view of a fully assembled stud A showing how the formed plates may connect the flanges with webs together, according to an embodiment of the present invention.

FIG. 6 shows an isometric elevation view of an alternate embodiment of the present invention which provides a secondary flange installed within either of the top or bottom flange with webs of the stud A for improved structural performance as well as improved fastener and external cantilevered load capabilities.

For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present application will, evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or conducted in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

Use of the phrases and/or terms such as but not limited to “exemplary embodiment,” “an embodiment,” “an alternate embodiment,” “one embodiment,” “another embodiment,” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A. B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

It is to be understood that the term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also contain one or more other components.

It is to be understood that the terms “steel stud” and “stud” are interchangeable throughout the disclosure, unless otherwise specified.

Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

According to a preferred embodiment of the present invention, an isometric elevation view of a stud A is shown in FIG. 1 . With reference to FIG. 1 , it is shown that the Stud A is comprising: a pair of top and bottom flanges with webs AA; multiple pairs of opposing formed plates AC, configured to be spaced along the length of the pair of top and bottom flanges with webs AA, hence to hold the top and bottom flanges together; and an insulation AB, adapted to be located full length inside of the Stud A, wherein the insulation AB is securely contained in place via the pair of top and bottom flanges with webs AA and the multiple pairs of opposing formed plates AC as shown in FIG. 1 .

Further referring to FIG. 1 , the pair of top and bottom flanges with webs AA, wherein each flange with respective web is comprised of: a flange 10, continuing to an inner web 14 at a bend 12 on both sides; the inner web 14 continuing to a step 16 on the both sides; an outer web 18 continuing from the step 16, terminates at a specified distance in an opposite direction of the step 16 on the both sides; a plurality of slots 26, located on the outer web 18 on the both sides, wherein the slots 26 are configured to stuck in both ends of each formed plate AC; and a plurality of aligned slots 28 provided over the flange 10, configured to make a bend by merely rolling the each of the flanges with webs over.

Continue referring to FIG. 1 , the pairs of opposing formed plates AC, wherein each formed plate is comprised of a web 20 and a pair of formed ends 22, wherein the termination of the formed ends 22 and an inner surface of the web 20 tightly contact the inside and outside of the outer web 18 of the top and bottom flanges with webs AA as shown in FIG. 1 .

In one embodiment, the pair of top and bottom flanges with webs AA is shown in the form of two strips parallel to each other with a space 24 therebetween as shown in FIG. 2 . Further referring to FIG. 2 , the slots 26 are shown extending along the length of each strip, at a specific distance apart from each other. Furthermore, the aligned slots 28 are shown extending the full length of each strip, and located adjacent to each other with a minimal distance, like a dashed line.

In one embodiment, each of the two strips of FIG. 2 is shown with the step 16 on each side as shown in FIG. 3 . The step 16 may be roll-formed into the strips of the respective flanges with webs AA.

In one embodiment, a semi formed stud A is shown in FIG. 4 . Now referring to FIG. 4 , the strips of the respective flanges with webs AA of FIG. 3 are shown, each with the bend 12 made at one side, and the insulation AB is installed therebetween the flanges with webs AA. Further, the other side of the flanges with webs AA is shown open as the bend is not yet made at the aligned slots 28 on the other side.

In further embodiment, the strips of the respective flanges with webs AA of FIG. 4 are shown with the bends on the other side in FIG. 5 that make the stud A almost fully assembled. The bends are made at the aligned slots 28 of the respective flanges with webs AA. In addition, FIG. 5 depicts the slots 26 to show that how the formed plates AC may connect the flanges with webs AA together.

In one embodiment, the stud A may not apply the formed plates AC to hold the flanges with webs AA together, for applications such as, non-load bearing conditions, wherein the webs of the flanges with webs AA may have small interior facing barbs, formed with a punch press, that penetrate the insulation AB to prevent separation of the flanges with webs AA, and to keep the insulation AB positioned therebetween the flanges with webs AA.

According to an alternate embodiment of the present invention, an isometric elevation view of the stud A with an additional secondary flange AD is shown in FIG. 6 . With reference to FIG. 6 , the secondary flange AD is comprised of a pair of legs 40, 42, and a web 44. The secondary flange AD may be located within the top, or the bottom or the both flanges of the stud A, and the insulation AB can be sized consequently to match with the secondary flange AD, Moreover, the insulation AB may also be located between the pair of legs 40, 42 of the secondary flange AD.

According to abovementioned embodiment, the secondary flange AD is configured to provide additional and separated penetration locations for mounting screws or fasteners, in order to allow multiple connection points on the screws or fasteners so that they become cantilevered and able to support loads unlike a single walled stud.

The present invention further discloses a manufacturing process of making the stud A. The manufacturing process comprises a plurality of process steps, including, but not limited to, decoiling of strip slack sections to form the pair of top and bottom flanges with webs AA; forming of the step 16 on each side of the strips of the top and bottom flanges via a roll-forming; forming of the bend 12 on each side of the strips of the top and bottom flanges via the plurality of aligned slots 28; foaming the insulation AB and final forming of the plurality of slots 26; installing the formed plates AC through the plurality of slots 26 to hold together the top and bottom flanges; and stacking and packaging of the stud A.

In one embodiment, the stud A may be made by employing a forming process that includes a use of compression around the different stud components, and use of electro-magnetic to control the positioning of the flanges with webs AA during a formed plate installation to ensure proper alignment with minimal tolerances to install the formed plates AC simultaneously at all locations on the stud A, along with alignment electronic controls.

In one embodiment, the manufacturing process may allow the final bends 12 at aligned perforations to be over-bent, pushing into the insulation AB, and recovering or springing-back to the correct angle, wherein the insulation AB may assist in maintaining the shape of the stud A, both during the forming process and once the stud A is ready for use.

In one embodiment, the steel stud A of the present invention may be made using galvanized steel in coil form, and fabricated/manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc. The stud A may also be made with multiple machines such as a turret press and brake press. Further, joining of the flange webs may be accomplished by using formed stainless-steel clips. The stud A may have additional holes, slots, ribs or other shapes traditionally used for “EQ” structural purposes, for reduction in thermal and acoustic transfer, for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners.

In one embodiment, the formed plates AC may be made up of a material such as stainless steel which is formed by a process similar to a cardboard box staple gun, wherein the gun forms the stainless steel as the steel is entering matching slots in the webs of the top and bottom flanges AA. The formed plates AC may have a plastic or other coating to help prevent vibration and acoustic transfer between the flanges with webs AA and the formed plates AC. In alternate embodiment, snap-in fiber reinforced plastic pultrusions, injection molded and extruded plastics, and other materials may be used in place of the stainless-steel formed plates, wherein the entry points into the slots of the webs of the top and bottom flanges AA are pointed and unidirectional “fingers” so that they will insert, but not easily be removed from the webs of the top and bottom flanges AA. 

1. A steel thermal stud, said stud comprising: a pair of top and bottom flanges with webs AA, wherein each flange with respective webs includes a flange continuing to an inner web at a bend on both sides, said inner web continuing to a step on the both sides, an outer web continuing from said step terminates at a specified distance in an opposite direction of said step on the both sides, a plurality of slots located on said outer web on the both sides, and a plurality of aligned slots provided over said flange; multiple pairs of opposing formed plates AC, configured to be spaced along length of said pair of top and bottom flanges with webs AA, hence to hold together said top and bottom flanges with webs AA; and an insulation AB, adapted to be located inside of said stud, wherein said insulation AB is securely contained in place via said pair of top and bottom flanges with webs AA and said multiple pairs of opposing formed plates AC.
 2. The stud of claim 1, wherein said plurality of aligned slots are configured to make said bend by merely rolling each of said top and bottom flanges with webs AA over.
 3. The stud of claim 1, wherein said pair of top and bottom flanges with webs AA may allow a fastener to penetrate in order to prevent the movement of said fastener in any direction, to prevent deformation of the stud wall material, to prevent said fastener from backing out by having additional contact with less potential movement, to provide more pull-out strength and more strip resistance of said fastener during installation.
 4. The stud of claim 1, wherein said each formed plate AC is comprised of a web and a pair of formed ends, and termination of said formed ends and an inner surface of said web tightly contact the inside and outside of said outer web of said top and bottom flanges with webs AA.
 5. The stud of claim 1, wherein said plurality of slots are configured to stuck in each formed end of each of said formed plates AC.
 6. The stud of claim 1, wherein said formed plates AC may help isolate and absorb vibration and thermal transfer, and assist with structural strengths.
 7. The stud of claim 1, may further comprise a secondary flange AD which is configured to be located within said top, or said bottom, or said top and bottom flanges with webs AA, to provide additional penetration locations for mounting screws or fasteners, in order to allow multiple connection points on said screws or fasteners hence to make said screws or fasteners cantilevered to support loads.
 8. The stud of claim 7, wherein said secondary flange AD is comprised of a pair of legs and a web.
 9. The stud of claim 1, may further comprises additional holes, slots, ribs or other shapes for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners.
 10. A method of manufacturing a steel thermal stud, said method comprising steps of: decoding of strip slack sections to form a pair of top and bottom flanges with webs AA; forming of a step on each side of said strips of said top and bottom flanges via a roll-forming; forming of a bend on each side of said strips of said top and bottom flanges via a plurality of aligned slots; foaming an insulation AB and forming of a plurality of slots; installing multiple pairs of opposing formed plates AC through said plurality of slots to hold together said top and bottom flanges; and stacking and packaging of said steel thermal stud.
 11. The method of claim 10, wherein said stud may be made by employing a forming process that includes a use of compression around the different stud components, and use of electro-magnetic to control the positioning of said top and bottom flanges with webs AA during a formed plate installation to ensure proper alignment with minimal tolerances to install said formed plates AC simultaneously at all locations on said stud, along with alignment electronic controls.
 12. The method of claim 10, wherein said manufacturing process may allow the final bends at aligned perforations to be over-bent, pushing into said insulation AB, and recovering or springing-back to the correct angle, wherein said insulation AB may assist in maintaining the shape of said stud, both during the forming process and once said stud is ready for use.
 13. The method of claim 10, wherein said steel stud may install a plastic spacer before forming of the final bend to prevent over-bending of the last-formed web when using light density insulation within said stud.
 14. The method of claim 10, wherein said steel stud may be made using galvanized steel in coil form, and manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc.
 15. The method of claim 10, wherein said steel stud may also be made with multiple machines such as a turret press and brake press.
 16. The method of claim 10, wherein said formed plates AC may be made up of a material such as stainless steel, snap-in fiber reinforced plastic pultrusions, injection molded and extruded plastics.
 17. The method of claim 10, wherein said formed plates AC may have a plastic or other coating to help prevent vibration and acoustic transfer between said top and bottom flanges with webs AA and said formed plates AC. 